WO2019169575A1

WO2019169575A1 - Article of clothing and manufacturing method thereof

Info

Publication number: WO2019169575A1
Application number: PCT/CN2018/078272
Authority: WO
Inventors: Zhenqiang Liu
Original assignee: Regina Miracle International (Group) Limited
Priority date: 2018-03-07
Filing date: 2018-03-07
Publication date: 2019-09-12
Also published as: US20200397064A1; WO2019170124A1; US11839241B2

Abstract

An article of clothing is disclosed. The article of clothing comprises a first fabric layer having an inner surface and an outer surface; and a second fabric layer having an inner surface and an outer surface. A thermoplastic material layer is joined to at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer. The thermoplastic layer is formed by hot pressing a thermoplastic material strip with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer.

Description

ARTCLE OF CLOTHING AND MANUFACTURING METHOD THEREOF

FIELD OF THE PRESENT DISCLOSURE

The present disclosure relates generally to articles of clothing, and in particular, to an article of clothing having one or more elastic portions formed therein.

BACKGROUND

Various garments, such as bras, T-shirts, pants, etc., incorporate elastic portions, for example around neck portion or in shoulder portion thereof. These elastic portions are capable of expanding and contracting, and thus may aid with supporting the garment against the body of a wearer. Conventionally, in order to allow for such expansion and contraction of the elastic portions, rubber material has been employed. The rubber material is often sewn or adhered to the portions of the garments that are to be made elastic. To wear or remove the garment, force is applied to the elastic portions, and the rubber material allows the elastic portions to expand to moderate elongations. Once the applied force to the elastic portions is removed, the rubber material causes the elastic portions to regain their original shape from the expanded state, thus providing a snug fit against the body of the wearer.

However, typical rubber material tends to lose its elastic properties after repeated stretching over a period of time. Once the rubber material losses its elastic properties, the elastic portions of the garment be likely to get loose, with limited or no expanding and contracting capabilities. Therefore, the garment after multiple uses may not be able to provide consistent expansion and/or contraction as desired by the wearer. Such garments often become unfit to be used, unless the rubber material is replaced with a new rubber material.

Accordingly, there is a need of article of clothing with elastic portions which can retain elastic properties even after repeated and prolonged usage, leading to an increase in overall life span of the garments.

SUMMARY

In one aspect, an article of clothing is disclosed. The article of clothing comprises a first fabric layer having an inner surface and an outer surface; and a second fabric layer having an inner surface and an outer surface. The article of clothing further comprises a thermoplastic layer joined to at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer.

In one or more embodiments, the thermoplastic layer is joined to at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer by hot pressing a thermoplastic material strip with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer.

In one or more embodiments, the thermoplastic material strip is formed by injection molding of thermoplastic material.

In one or more embodiments, the thermoplastic material strip includes perforations formed therein.

In one or more embodiments, the thermoplastic layer is joined to the inner surface of the first fabric layer and the inner surface of the second fabric layer.

In one or more embodiments, the thermoplastic layer is joined to the inner surface of the first fabric layer and the outer surface of the second fabric layer.

In one or more embodiments, the first fabric layer and the second fabric layer are portions of a fabric sheet, and defined by folding thereof.

In one or more embodiments, the article of clothing further comprises a folded fabric sheet joined to the outer surface of the first fabric layer and the outer surface of the second fabric layer, such that the thermoplastic layer is enclosed between the fabric sheet and the folded fabric sheet.

In one or more embodiments, free edges of the fabric sheet are joined by ultrasonic welding.

In one or more embodiments, the article of clothing further comprises a rubber layer joined to at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer using one or more adhesive layers.

In another aspect, a method of manufacturing an article of clothing having a fabric layer is disclosed. The method comprises providing a fabric sheet. The method further comprises providing a thermoplastic material strip. The method further comprises hot pressing the thermoplastic material strip with the fabric sheet, such that a thermoplastic layer is formed on the fabric sheet.

In one or more embodiments, the fabric sheet is folded to define a first fabric layer and a second fabric layer therein, and wherein the thermoplastic layer is hot pressed with at least one of an inner surface of the first fabric layer and an inner surface of the second fabric layer.

In one or more embodiments, the thermoplastic layer is hot pressed with the inner surface of the first fabric layer and the inner surface of the second fabric layer.

In one or more embodiments, the thermoplastic layer is hot pressed with the inner surface of the first fabric layer and an outer surface of the second fabric layer.

In one or more embodiments, the method further comprises providing a folded fabric sheet, wherein the folded fabric sheet is hot pressed with the outer surface of the first fabric layer and the outer surface of the second fabric layer, such that the thermoplastic layer is enclosed between the fabric sheet and the folded fabric sheet.

In one or more embodiments, the method further comprises providing a rubber layer, wherein the rubber layer is hot pressed with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer using one or more adhesive layers.

In one or more embodiments, the method further comprises joining free ends of the fabric sheet by ultrasonic welding.

In yet another aspect, an article of clothing is disclosed. The article of clothing comprises a body structure and one or more elastic portions formed along one or more edges of the body structure. The one or more elastic portions comprise a first fabric layer having an inner surface and an outer surface; and a second fabric layer having an inner surface and an outer surface. The one or more elastic portions further comprise a thermoplastic layer joined to at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer.

In still another aspect, a brassiere is disclosed. The brassiere comprises a pair of bra cups. The brassiere also comprises a pair of side wings having a fabric sheet joined to the pair of bra cups. The brassiere further comprises a thermoplastic layer joined to the fabric sheet along a bottom edge of the pair of side wings.

In one or more embodiments, the fabric sheet is folded along the bottom edge of the pair of side wings to define a first fabric layer having an inner surface and an outer surface and a second fabric layer having an inner surface and an outer surface such that the inner surface of the first fabric layer is facing the inner surface of the second fabric layer, and the thermoplastic layer is disposed between and joined to the inner surface of the first fabric layer and the inner surface of the second fabric layer.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of example embodiments of the present disclosure, reference is now made to the following descriptions taken in connection with the accompanying drawings in which:

FIG. 1 illustrates a diagrammatic view of an article of clothing with an elastic portion therein, in accordance with one or more embodiments of the present disclosure;

FIG. 2 illustrates a diagrammatic view of an arrangement of various layers for forming the elastic portion along with a manufacturing setup therefor, in accordance with a first embodiment of the present disclosure;

FIG. 3 illustrates a diagrammatic view of an arrangement of various layers for forming the elastic portion, in accordance with a second embodiment of the present disclosure;

FIG. 4 illustrates a diagrammatic view of an arrangement of various layers for forming the elastic portion, in accordance with a third embodiment of the present disclosure;

FIG. 5 illustrates a diagrammatic view of an arrangement of various layers for forming the elastic portion, in accordance with a fourth embodiment of the present disclosure;

FIG. 6 illustrates a diagrammatic view of an arrangement of various layers for forming the elastic portion, in accordance with a fifth embodiment of the present disclosure;

FIG. 7 illustrates a diagrammatic view of an arrangement of various layers for forming the elastic portion, in accordance with a sixth embodiment of the present disclosure;

FIG. 8 illustrates a diagrammatic view of an arrangement of various layers for forming the elastic portion, in accordance with a seventh embodiment of the present disclosure;

FIG. 9 illustrates a diagrammatic view of an arrangement of various layers for forming the elastic portion, in accordance with an eighth embodiment of the present disclosure;

FIG. 10 illustrates a diagrammatic view of an arrangement of various layers for forming the elastic portion, in accordance with a ninth embodiment of the present disclosure;

FIG. 11 illustrates a diagrammatic view of an arrangement of various layers for forming the elastic portion, in accordance with a tenth embodiment of the present disclosure;

FIG. 12 illustrates a diagrammatic view of an arrangement of various layers for forming the elastic portion, in accordance with one or more embodiments of the present disclosure;

FIG. 13 illustrates a diagrammatic view of an arrangement of various layers for forming the elastic portion, in accordance with one or more embodiments of the present disclosure;

FIG. 14 illustrates a diagrammatic view of an exemplary article of clothing, in accordance with one or more embodiments of the present disclosure;

FIG. 15 illustrates a diagrammatic view of an exemplary article of clothing, in accordance with one or more embodiments of the present disclosure;

FIG. 16 illustrates a diagrammatic view of an exemplary article of clothing, in accordance with one or more embodiments of the present disclosure;

FIG. 17 illustrates a diagrammatic view of an exemplary article of clothing, in accordance with one or more embodiments of the present disclosure; and

FIG. 18 illustrates a diagrammatic view of an exemplary article of clothing, in accordance with one or more embodiments of the present disclosure.

DETAILED DESCRIPTION

In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one skilled in the art that the present disclosure can be practiced without these specific details. In other instances, apparatuses and methods are shown in block diagram form only in order to avoid obscuring the present disclosure.

Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearance of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not for other embodiments.

The embodiments are described herein for illustrative purposes and are subject to many variations. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but are intended to cover the application or implementation without departing from the spirit or the scope of the present disclosure. Further, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting. Any heading utilized within this description is for convenience only and has no legal or limiting effect.

Where there is reference to the word “layer” it is to be understood that it may have its common definition and, but not limited to that the layer could consist of one panel or may have regions that are defined by two or more panels that are joined and that may each be of a different characteristic (e.g. color, thickness, material, orientation, size) .

Referring to the drawings, FIG. 1A illustrates a diagrammatic view of an article of clothing 10, in accordance with one or more embodiments of the present disclosure. The article of clothing 10 may be any garment to be worn by a wearer. For example, the article of clothing 10 may be, but not limited to, a brassiere, a bra top, a sports top, a pantie, a T-shirt, a pant, and the like. In the exemplary illustration of FIG. 1A, the article of clothing 10 is shown to be a brassiere. The article of clothing 10 includes a body structure 12 which defines shape and purpose of the article of clothing 10. In the exemplary article of clothing 10 of FIG. 1, the body structure 12 includes a pair of bra cups, with a first bra cup 14a and a second bra cup 14b. A center gore 16 is extending between and connects the first bra cup 14a and the second bra cup 14b. A pair of straps, including a first strap 18a and a second strap 18b are attached to peripheries of the first bra cup 14a and the second bra cup 14b, respectively. Further, a pair of side wings, including a first side wing 20a and a second side wing 20b are attached to the peripheries of the first bra cup 14a and the second bra cup 14b, respectively. In one or more examples, one or more fasteners 21 may be provided with one or more of the first side wing 20a and the second side wing 20b. It may be contemplated that the pair of

straps

18a and 18b support the article of clothing 10 on shoulders of the wearer, while the pair of

side wings

20a and 20b support the article of clothing 10 around a torso of the wearer. In some examples, the pair of

straps

18a and 18b may not be provided and only the pair of

side wings

20a and 20b may support the article of clothing 10 on the wearer.

As illustrated in FIG. 1A, the body structure 12 provides one or more edges, including an edge 22. In the illustrated examples, the edge 22 is shown to be extending along a bottom of the pair of

side wings

20a and 20b of the body structure 12, in the article of clothing 100. For such cases, the edge 22 has been, sometimes, interchangeably referred to as “bottom edge 22” without any limitations. It may be understood that although the edge 22 is shown to be extending along the bottom of the body structure 12; in other examples, the edge 22 may be any other edge, such as, a side edge or a top edge, of the body structure 12 without any limitations. According to an embodiment of the present disclosure, the article of clothing 10 includes an elastic portion 100 formed along and co-extensive with the edge 22 of the body structure 12. The elastic portion 100 may be extending along the entire length of the edge 22 of the body structure 12. In some examples, the article of clothing 10 may have multiple elastic portions 100 formed along various edges thereof. For instance, in one example, the pair of

straps

18a and 18b may function as the elastic portions 100 in the article of clothing 10. The elastic portion 100 allows the article of clothing 10 to expand and contract. It may be understood that the body structure 12 provides the external appearance to the article of clothing 10 and the incorporated elastic portions 100 allow the article of clothing 10 to be worn and removed conveniently.

FIG. 1B illustrates a section view of the elastic portion 100 taken along a line A-A’ of FIG. 1A, in accordance with one or more embodiments of the present disclosure. As illustrated in FIG. 1B, the elastic portion 100 may include multiple layers. According to an embodiment of the present disclosure, the elastic portion 100, in the article of clothing 10, may include a fabric sheet 102 (also shown in FIG. 1A) . The fabric sheet 102 forms part of the pair of

side wings

20a and 20b, and is extending up to the edge 22 where the fabric sheet 102 is folded to define a first fabric layer 104 and a second fabric layer 106; with the first fabric layer 104 having an inner surface 104a and an outer surface 104b, and the second fabric layer 106 having an inner surface 106a and an outer surface 106b. The first fabric layer 104 and the second fabric layer 106 are disposed such that the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106 are facing each other, and the outer surface 104b of the first fabric layer 104 and the outer surface 106b of the second fabric layer 106 form part of an exterior surface for the elastic portion 100. In some examples, the fabric sheet 102, and thereby each of the first fabric layer 104 and the second fabric layer 106, may be a laminate (not shown) having a fabric panel and a foam panel laminated to each other.

In one or more examples, the first fabric layer 104 and the second fabric layer 106 are portions of the fabric sheet 102, and are defined by folding of the fabric sheet 102. In alternative examples, the first fabric layer 104 and the second fabric layer 106 may be separate fabric layers and are connected to each other by suitable methods known in the art, such as, but not limited to, sewing, adhesion, ultrasonic welding, etc., to complete the fabric sheet 102. Typically, each of the first fabric layer 104 and the second fabric layer 106 may be composed of same material. However, the first fabric layer 104 and the second fabric layer 106 may be composed of different materials without any limitations. In the present examples, the first fabric layer 104 and the second fabric layer 106 may be composed of nylon material. It shall be appreciated that one or more of the first fabric layer 104 and the second fabric layer 106 may extend in width beyond a width of the elastic portion 100 (i.e. orthogonal to the direction of extension of the elastic portion 100 along the edge 22) and form part of the body structure 12 of the article of clothing 10.

Further, as illustrated in FIG. 1B, the elastic portion 100 includes a thermoplastic layer 108, in accordance with embodiments of the present disclosure. In the present embodiments, the thermoplastic layer 108 is joined to the fabric sheet 102. Specifically, the thermoplastic layer 108 is joined to at least one of the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106. As illustrated, the thermoplastic layer 108 is generally sandwiched between the first fabric layer 104 and the second fabric layer 106. Referring to FIGS. 1A and FIG. 1B in combination, in some examples, the thermoplastic layer 108, in the elastic portion 100, may be continuous throughout the length of the edge 22 spanning the first side wing 20a, the center gore 16 and the second side wing 20b, in the article of clothing 10. In other examples, the thermoplastic layer 108, in the elastic portion 100, may be non-continuous and be divided in three separate parts for each of the first side wing 20a, the center gore 16 and the second side wing 20b, in the article of clothing 10.

In one or more embodiments, the elastic portion 100 may, optionally, include a rubber layer 110 sandwiched between the first fabric layer 104 and the second fabric layer 106. In one or more examples, the rubber layer 110 may be composed of Spandex material. In other examples, the rubber layer 110 may be composed of other elastic materials without any limitations. It may be seen that the rubber layer 110 is generally located adjacent to the thermoplastic layer 108; however, in other examples, the rubber layer 110 may be separate from the thermoplastic layer 108 (as shown in FIG. 1B) . In the present examples, both the thermoplastic layer 108 and the rubber layer 110 are co-extensive in the elastic portion 100. In such embodiments, the elastic portion 100 may also include one or more adhesive layers 112 provided with the rubber layer 110. In the elastic portion 100, the rubber layer 110 is joined to at least one of the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106 using one or more adhesive layers 112.

FIG. 2 illustrates a manufacturing setup 24 for joining the thermoplastic layer 108 to the fabric sheet 102. The manufacturing setup 24 is utilized for implementing hot pressing process. The manufacturing setup 24 includes a first die 26 and a second die 28 which are pressed against each other at a suitably high temperature for implementing the hot pressing process. It may be contemplated, although not illustrated, that there may be a power supply means, such as a hydraulic power supply means, to provide power for pressing of the first die 26 and the second die 28 against each other. In alternative embodiments of the present disclosure, only one of the first die 26 and the second die 28 may be employed for hot pressing process.

According to an embodiment of the present disclosure, the thermoplastic layer 108 is formed with the fabric sheet 102 by hot pressing a thermoplastic material strip 150 on the fabric sheet 102. Specifically, the thermoplastic layer 108 is joined to at least one of the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106 by hot pressing the thermoplastic material strip 150 with at least one of the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106. In one embodiment, the thermoplastic layer 108 is joined to the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106. In alternative embodiment, the thermoplastic layer 108 is joined to the inner surface 104a of the first fabric layer 104 and the outer surface 106b of the second fabric layer 106.

Due to such hot pressing of the thermoplastic material strip 150 with the fabric sheet 102, the substantially stretchable thermoplastic layer 108 is formed with the fabric sheet 102. The substantially stretchable thermoplastic layer 108 in the elastic portion 100 of the article of clothing 10 allows the article of clothing 10 to stretch to moderate elongations at the edge 22 once an external force is applied thereon, and regain its original length once the external force applied thereon is removed. It may be understood that when hot pressed, the thermoplastic material strip 150 may be embedded with the fabric sheet 102 to form the thermoplastic layer 108. No adhesive is required to join the thermoplastic layer 108 with the fabric sheet 102 or with the first fabric layer 104 or the second fabric layer 106. Owing to hot pressing of the thermoplastic material strip 150, the thermoplastic material infiltrates into the fabric sheet 102 in the surface (s) to which the thermoplastic material strip 150 is in contact with. The infiltration of the thermoplastic material allows for permanent joining of the thermoplastic material strip 150 with the fabric sheet 102, forming the thermoplastic layer 108 therewith. Further, in one or more examples, the thermoplastic material strip 150 may include a plurality of perforations (not shown) formed therein. Therefore, when the thermoplastic material strip 150 is hot pressed to form the thermoplastic layer 108, the formed thermoplastic layer 108 may have a plurality of perforations. The perforations in the thermoplastic layer 108, along with the first fabric layer 104 and the second fabric layer 106, allows for ventilation through the elastic portion 100 in the article of clothing 10.

In one example, the thermoplastic material strip 150 is generally in the shape of a thin rectangular strip of a certain thickness. In alternative examples, the thermoplastic material strip 150 may be of any other suitable shape and size as per the requirements of the elastic portion 100 to be formed therewith and used in the article of clothing 10. In an embodiment of the present disclosure, the thermoplastic material strip 150 is formed by injection molding of a thermoplastic material. The injection molding allows the thermoplastic material strip 150 to be formed into various shapes and sizes depending upon the shape and size of the required thermoplastic layer 108 to be formed therefrom. In alternative embodiments, the thermoplastic material strip 150 may be formed by any other suitable process.

Thermoplastic materials, also sometimes referred to as thermoplastic elastomers (TPE) or thermoplastic rubbers (TPR) , are a class of copolymers or a physical mix of polymers (usually a plastic and a rubber) which consist of materials with both thermoplastic and elastomeric properties. Thermoplastic materials show advantages typical of both rubbery materials and plastic materials. The benefit of using thermoplastic materials is the ability to stretch to moderate elongations and return to its near original shape creating a longer life and better physical range than other materials. Examples of thermoplastic materials which are widely available in the market include, but not limited to, Hytrel, Dryflex, Mediprene, Kraton, Pibiflex, Sofprene, Laprene, Sofprene, Dryflex, Santoprene, Termoton, Solprene, etc., to name a few.

It may be understood that the multiple layers of the elastic portion 100 may be arranged in various manners. FIGS. 2-13 illustrate different arrangement or configurations of the multiple layers for forming the elastic portion 100 of the article of clothing 10. In particular, FIGS. 2-13 provide different methods for joining the fabric sheet 102 and the thermoplastic material strip 150 embedded therewith. The arrangements shown in FIGS. 2-13 are exemplary only and non-exhaustive, and other arrangements for forming the elastic portion 100 by hot pressing may be possible without any limitations. Also, although the manufacturing setup 24 is only shown in FIG. 2, it may be understood that the similar manufacturing setups may be utilized with arrangements of FIGS. 2-13 for carrying out the hot pressing process for forming the elastic portion 100. It may be understood that FIGS. 2-13 only show a section of to be formed elastic portion 100, and the elastic portion 100 may be extending along its longitudinal direction (i.e. in the direction orthogonal to the plane of sheet of the drawings) . Generally, in such arrangements, at least one of the first fabric layer 104 and the second fabric layer 106 is larger than the thermoplastic material strip 150 along both the longitudinal direction as well as the lateral direction thereof, thus allowing to enclose the thermoplastic layer 108 when formed by hot pressing of the thermoplastic material strip 150. As illustrated, the thermoplastic material strip 150 is generally arranged flushed with one or more of the free ends of the first fabric layer 104 and the second fabric layer 106. Thus, as may be contemplated, the formed thermoplastic layer 108 is generally located between the first fabric layer 104 and the second fabric layer 106, and is flushed with an upper edge of the elastic portion 100. The formed thermoplastic layer 108 is co-extensive along the length of the edge 22 in the article of clothing 100. Further, in various examples, free ends of the first fabric layer 104 and the second fabric layer 106, in the fabric sheet 102, may be joined together by using ultrasonic welding technique. Alternatively, the free ends of the first fabric layer 104 and the second fabric layer 106, in the fabric sheet 102, may be joined together using any other suitable means, such as using adhesive, sewing, etc.

FIG. 2 illustrates an arrangement 200 of the various layers for forming the elastic portion 100 when hot pressed, in accordance with a first embodiment of the present disclosure. As shown in FIG. 2, the first fabric layer 104 and the second fabric layer 106 are portions of the fabric sheet 102, and are defined by folding of the fabric sheet 102 along a folded region 202. The folding of the fabric sheet 102 is done such that the thermoplastic material strip 150 is disposed between the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106. As illustrated, the second fabric layer 106 is generally larger in dimensions as compared to the first fabric layer 104. The second fabric layer 106 is dimensioned to be of suitable size for enclosing the thermoplastic material strip 150 when joined with the first fabric layer 104. Further, the folding of the fabric sheet 102 provides two

free ends

204a and 204b. The free end 204a of the first fabric layer 104 is joined to the inner surface 106a of the second fabric layer 106 in the hot pressing process.

In one example, the free end 204b of the second fabric layer 106 may be joined with the pair of

side wings

20a and 20b in order for securing the formed elastic portion 100 with the body structure 12 along the edge 22, to complete the article of clothing 10. In other examples, the second fabric layer 106, from the elastic portion 100, may be continuous and is an extension of the fabric of the pair of

side wings

20a and 20b, and is folded to form the first fabric layer 104, and then formed into the elastic portion 100 (as discussed above) which as a result would be continuous with the body structure 12 along the edge 22, to complete the article of clothing 10. In the given examples, either of the first fabric layer 104 or the second fabric layer 106 may be disposed towards an inner side of the article of clothing 100, the said inner side being the one relatively nearer to the body of the wearer as compared to an outer side when the article of clothing 100 is worn. It may be contemplated that in the disclosed arrangements, the first fabric layer 104 and the second fabric layer 106 may be reversed without any limitations.

FIG. 3 illustrates an arrangement 300 of the various layers for forming the elastic portion 100 when hot pressed, in accordance with a second embodiment of the present disclosure. As shown in FIG. 3, the first fabric layer 104 and the second fabric layer 106 are portions of the fabric sheet 102, and are defined by folding of the fabric sheet 102 along a folded region 302. Also as may be seen, the fabric sheet 102 is further folded along a folded region 304, such that the inner surface 104a of the first fabric layer 104 is facing the outer surface 106b of the second fabric layer 106 at their respective

free ends

306a and 306b. The thermoplastic material strip 150 is disposed proximal to the folded region 302 between the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106. Further, the adhesive layer 112 is provided proximal to the folded region 304 between the inner surface 104a of the first fabric layer 104 and the outer surface 106b of the second fabric layer 106.

FIG. 4 illustrates an arrangement 400 of the various layers for forming the elastic portion 100 when hot pressed, in accordance with a third embodiment of the present disclosure. As shown in FIG. 4, the first fabric layer 104 and the second fabric layer 106 are portions of the fabric sheet 102, and are defined by folding of the fabric sheet 102 along a folded region 402 and a folded region 404, such that the inner surface 104a of the first fabric layer 104 is facing the inner surface 106a of the second fabric layer 106. The thermoplastic material strip 150 is disposed proximal to the folded region 402 between the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106. Further, the adhesive layer 112 is provided proximal to the folded region 404 between the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106.

FIG. 5 illustrates an arrangement 500 of the various layers for forming the elastic portion 100 when hot pressed, in accordance with a fourth embodiment of the present disclosure. As shown in FIG. 5, similar to the arrangement 300, the first fabric layer 104 and the second fabric layer 106 are portions of the fabric sheet 102, and are defined by folding of the fabric sheet 102 along a folded region 502. The fabric sheet 102 is further folded along a folded region 504, such that the inner surface 104a of the first fabric layer 104 is facing the outer surface 106b of the second fabric layer 106 at their respective

free ends

506a and 506b. The thermoplastic material strip 150 is disposed proximal to the folded region 502 between the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106. Further, the rubber layer 110 and the two adhesive layers 112 on each side of the rubber layer 110 are provided proximal to the folded region 504 between the inner surface 104a of the first fabric layer 104 and the outer surface 106b of the second fabric layer 106.

FIG. 6 illustrates an arrangement 600 of the various layers for forming the elastic portion 100 when hot pressed, in accordance with a fifth embodiment of the present disclosure. As shown in FIG. 6, the first fabric layer 104 and the second fabric layer 106 are portions of the fabric sheet 102, and are defined by folding of the fabric sheet 102 along a folded region 602, such that the inner surface 104a of the first fabric layer 104 is facing the inner surface 106a of the second fabric layer 106. The thermoplastic material strip 150 is disposed proximal to the folded region 602 between the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106. Further, a folded fabric sheet 604 is provided which is to be joined to the outer surface 104b of the first fabric layer 104 and the outer surface 106b of the second fabric layer 106.

FIG. 7 illustrates an arrangement 700 of the various layers for forming the elastic portion 100 when hot pressed, in accordance with a sixth embodiment of the present disclosure. As shown in FIG. 4, the first fabric layer 104 and the second fabric layer 106 are portions of the fabric sheet 102, and are defined by folding of the fabric sheet 102 along a folded region 702 and a folded region 704, such that the inner surface 104a of the first fabric layer 104 is facing the inner surface 106a of the second fabric layer 106. Free ends (not shown) of the fabric sheet 102 may be joined together by ultrasonic welding process or the like, to complete a loop. Two thermoplastic material strips 150 are disposed proximal to each of the folded region 702 and the folded region 704 between the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106.

FIG. 8 illustrates an arrangement 800 of the various layers for forming the elastic portion 100 when hot pressed, in accordance with a seventh embodiment of the present disclosure. As shown in FIG. 8, similar to the arrangement 400, the first fabric layer 104 and the second fabric layer 106 are portions of the fabric sheet 102, and are defined by folding of the fabric sheet 102 along a folded region 802 and a folded region 804, such that the inner surface 104a of the first fabric layer 104 is facing the inner surface 106a of the second fabric layer 106. The thermoplastic material strip 150 is disposed proximal to the folded region 802 between the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106. Further, the rubber layer 110 and the two adhesive layers 112 on each side of the rubber layer 110 are provided proximal to the folded region 804.

FIG. 9 illustrates an arrangement 900 of the various layers for forming the elastic portion 100 when hot pressed, in accordance with an eighth embodiment of the present disclosure. As shown in FIG. 9, the first fabric layer 104 and the second fabric layer 106 are portions of the fabric sheet 102, and are defined by folding of the fabric sheet 102 along a folded region 902, such that the inner surface 104a of the first fabric layer 104 is facing the inner surface 106a of the second fabric layer 106. The thermoplastic material strip 150 is disposed proximal to the folded region 902 between the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106. Further, the rubber layer 110 and the two adhesive layers 112 on each side of the rubber layer 110 are provided proximal to

free ends

906a and 906b between the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106.

FIG. 10 illustrates an arrangement 1000 of the various layers for forming the elastic portion 100 when hot pressed, in accordance with a ninth embodiment of the present disclosure. As shown in FIG. 10, the first fabric layer 104 and the second fabric layer 106 are in the form of planar sheets which are separate from each other. The first fabric layer 104 and the second fabric layer 106 are disposed with the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106 facing opposite to each other. The thermoplastic material strip 150 is disposed between the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106.

FIG. 11 illustrates an arrangement 1100 of the various layers for forming the elastic portion 100 when hot pressed, in accordance with a tenth embodiment of the present disclosure. As shown in FIG. 11, the first fabric layer 104 and the second fabric layer 106 are portions of the fabric sheet 102, and are defined by folding of the fabric sheet 102 along a folded region 1102 and a folded region 1104, such that the inner surface 104a of the first fabric layer 104 is facing the inner surface 106a of the second fabric layer 106. Free ends (not shown) of the fabric sheet 102 may be joined together by ultrasonic welding process or the like, to complete a loop. A single block of the thermoplastic material strip 150, extending between the folded region 1102 and the folded region 1104, is disposed between the inner surface 104a of the first fabric layer 104 and the inner surface 106a of the second fabric layer 106.

As noted earlier, any one of the

arrangements

200, 300, 400, 500, 600, 700, 800, 900, 1000 and 1100 when hot pressed may provide the elastic portion 100 with the thermoplastic player 108 formed therein. In particular, the

arrangements

200, 300, 400, 500, 600, 700, 800 and 900 may be hot pressed for forming the elastic portion 100 to be disposed along the bottom edge 22 of the article of clothing 10; and, the

arrangements

1000 and 1100 may be hot pressed for forming the elastic portion 100 to be disposed along with, for example, the first strap 18a and the second strap 18b, in the article of clothing 10. It may be understood that wherever the rubber layer 110, with or without the one or more adhesive layers 112, is being utilized in formation of the elastic portion 100, such rubber layer, along with the corresponding one or more adhesive layers, may be replaced with an additional thermoplastic layer, such as the thermoplastic layer 108.

Referring now to the embodiment disclosed in FIG. 12, an arrangement 1200 has been illustrated for forming the elastic portion 100. In the arrangement 1200, the first fabric layer 104, the adhesive layer 112, the thermoplastic material strip 150, and the second fabric layer 106 stacked in sequential order. The first fabric layer 104 and the second fabric layer 106 are joined with each other at a seam 1202. Specifically, at the seam 1202, the outer surface 104b of the first fabric layer 104 and the outer surface 106b of the second fabric layer 106 are joined together by ultrasonic welding. Further, a fastening arrangement including, for example, hook and loop fasteners 1204, may be provided on the outer surface 104b of the first fabric layer 104. For this purpose, a non-stretchable pad layer 1206 may be provided above the thermoplastic material strip 150 to which the hook and loop fasteners 1204 are attached and the first fabric layer 104 may include slits (not shown) to allow for the hook and loop fasteners 1204 to pass therethrough and be exposed on the outer surface 104b of the first fabric layer 104. Similarly, in the embodiment disclosed in FIG. 13, an arrangement 1300 has been illustrated for forming the elastic portion 100. In the arrangement 1300, the first fabric layer 104, the adhesive layer 112, the thermoplastic material strip 150, and the second fabric layer 106 stacked in sequential order. The first fabric layer 104 and the second fabric layer 106 are joined with each other at a seam 1302 from one side and at a seam 1304 at other side. Specifically, at the

seams

1302 and 1304, the outer surface 104b of the first fabric layer 104 and the outer surface 106b of the second fabric layer 106 are joined together by ultrasonic welding. Further, a fastening arrangement including, for example, hook and loop fasteners 1306, may be provided on the outer surface 104b of the first fabric layer 104. For this purpose, a non-stretchable pad layer 1308 may be provided above the thermoplastic material strip 150 to which the hook and loop fasteners 1306 are attached and the first fabric layer 104 may include slits (not shown) to allow for the hook and loop fasteners 1306 to pass therethrough and be exposed on the outer surface 104b of the first fabric layer 104. The elastic portion 100 formed from the

arrangements

1200 and 1300, when hot pressed, may be particularly implemented as the fasteners 21, in the article of clothing 10.

In examples as illustrated in FIGS. 14 and 15, the article of clothing 10 is shown to be a bra top. The elastic portion 100, with the thermoplastic layer 108 therein, is provided along a bottom edge thereof. In some examples, the elastic portion 100 may also be provided on shoulder straps (not labelled) of the article of clothing 10. In another example disclosed in FIG. 16, the article of clothing 10 is shown to be an underwear. In this example, the elastic portion 100, with the thermoplastic layer 108 therein, is formed along a waist line of the article of clothing 10. Similarly, in example of FIG. 17 in which the article of clothing 10 is shown to a pant, the elastic portion 100, with the thermoplastic layer 108 therein, is formed at a waistline thereof. In another example as disclosed in FIG. 18 in which the article of clothing 10 is shown to be a T-shirt, multiple elastic portions 100, with the corresponding thermoplastic layers 108 therein, are provided and located at one or more locations, such as, but not limited to, waistline, neckline, end of arms, etc.

The elastic portion 100, with the thermoplastic layer 108 therein, allows the corresponding edge 22 along which it is extending, to expand and contract in the article of clothing 10 on application of force. Since the thermoplastic material retains its elastic properties over a long period of time, the garments 10, such as the garments 10 illustrated in FIGS. 14, 15, 16, 17 and 18 utilizing the elastic portion 100 of the present disclosure, remain usable over a long period of time. The implementation of thermoplastic layer 108 may result in better elastic properties while eliminating the need of using adhesives for securing the two

fabric layers

104 and 106 in the elastic portion 100. Further, the elastic portion 100 with the disclosed thermoplastic layer 108 provides a stiff feeling to the wearer and a hard appearance from the outside for the article of clothing 10, which is desirable. Further, the thermoplastic layer 108 in the elastic portion 100 may provide good “hand feel, ” i.e., a soft touch for the elastic portion 100 compared to utilizing conventional elastic materials, such as rubber. As discussed earlier, in some cases, only one of the first fabric layer 104 and the second fabric layer 106 is present and the thermoplastic layer 108 is covered by the

present fabric layer

104 or 106 on one side only, such that the other side of the thermoplastic layer 108 is exposed. In such cases, in which the thermoplastic layer 108 in the elastic portion 100 is not covered on both sides by the fabric layers 104 and 106, the exposed thermoplastic layer 108 in the elastic portion 100 provides an anti-skid effect against, for example, the skin of the wearer which may be desirable in appropriate circumstances. Preferably, such exposed thermoplastic layer 108 is located on the inner side of the article of clothing 100 to avoid undesirable outlook and in order to impart the said anti-skid effect in the article of clothing 100.

The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the present disclosure and its practical application, to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated.

Claims

An article of clothing comprising:

a first fabric layer having an inner surface and an outer surface;

a second fabric layer having an inner surface and an outer surface; and

a thermoplastic layer joined to at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer.
The article of clothing of claim 1, wherein the thermoplastic layer is joined to at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer by hot pressing a thermoplastic material strip with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer.
The article of clothing of claim 2, wherein the thermoplastic material strip is formed by injection molding of thermoplastic material.
The article of clothing of claim 2, wherein the thermoplastic material strip includes perforations formed therein.
The article of clothing of claim 1, wherein the thermoplastic layer is joined to the inner surface of the first fabric layer and the inner surface of the second fabric layer.
The article of clothing of claim 1, wherein the thermoplastic layer is joined to the inner surface of the first fabric layer and the outer surface of the second fabric layer.
The article of clothing of claim 1, wherein the first fabric layer and the second fabric layer are portions of a fabric sheet, and defined by folding thereof.
The article of clothing of claim 7 further comprising a folded fabric sheet joined to the outer surface of the first fabric layer and the outer surface of the second fabric layer, such that the thermoplastic layer is enclosed between the fabric sheet and the folded fabric sheet.
The article of clothing of claim 7, wherein free edges of the fabric sheet are joined by ultrasonic welding.
The article of clothing of claim 1 further comprising a rubber layer joined to at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer using one or more adhesive layers.
A method of manufacturing an article of clothing, the method comprising;

providing a fabric sheet;

providing a thermoplastic material strip; and

hot pressing the thermoplastic material strip with the fabric sheet, such that a thermoplastic layer is formed on the fabric sheet.
The method of claim 11, wherein the thermoplastic material strip is formed by injection molding of thermoplastic material.
The method of claim 11, wherein the thermoplastic material strip includes perforations formed therein.
The method of claim 11, wherein the fabric sheet is folded to define a first fabric layer and a second fabric layer therein, and wherein the thermoplastic layer is hot pressed with at least one of an inner surface of the first fabric layer and an inner surface of the second fabric layer.
The method of claim 14, wherein the thermoplastic layer is hot pressed with the inner surface of the first fabric layer and the inner surface of the second fabric layer.
The method of claim 14, wherein the thermoplastic layer is hot pressed with the inner surface of the first fabric layer and an outer surface of the second fabric layer.
The method of claim 14 further comprising providing a folded fabric sheet, wherein the folded fabric sheet is hot pressed with the outer surface of the first fabric layer and the outer surface of the second fabric layer, such that the thermoplastic layer is enclosed between the fabric sheet and the folded fabric sheet.
The method of claim 14 further comprising providing a rubber layer, wherein the rubber layer is hot pressed with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer using one or more adhesive layers.
The method of claim 9 further comprising joining free ends of the fabric sheet by ultrasonic welding.
An article of clothing comprising:

a body structure; and

one or more elastic portions formed along one or more edges of the body structure, the one or more elastic portions comprising:

a first fabric layer having an inner surface and an outer surface;

a second fabric layer having an inner surface and an outer surface; and

a thermoplastic layer joined to at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer.
A brassiere, comprising:

a pair of bra cups;

a pair of side wings having a fabric sheet joined to the pair of bra cups; and

a thermoplastic layer joined to the fabric sheet along a bottom edge of the pair of side wings.
The brassiere of claim 21, wherein the fabric sheet is folded along the bottom edge of the pair of side wings to define a first fabric layer having an inner surface and an outer surface and a second fabric layer having an inner surface and an outer surface such that the inner surface of the first fabric layer is facing the inner surface of the second fabric layer, and wherein the thermoplastic layer is disposed between and joined to the inner surface of the first fabric layer and the inner surface of the second fabric layer.